Compliance West HT-2800 User manual

HT-2800
Dielectric Withstand Tester
0-2800 Volts DC Output
Instruction Manual
COMPLIANCE
WESTUSA

Rev. 2.4 August 20, 2007 i
Dear Customer:
Congratulations! Compliance West USA is proud to present you
with your Dielectric Withstand Tester. Your instrument features
a groundbreaking logic-controlled circuit design and ergonomic
front panel and represents the latest in high voltage production
line testing.
To fully appreciate all the features of your new meter, we
suggest that you take a few moments to review this manual.
Compliance West USA stands by your instrument with a full one-
year warranty and a loaner instrument policy. If the need arises,
please don't hesitate to call on us.
Thank you for your trust and confidence.

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Table of Contents
An Introduction to Dielectric Withstand Testing with the HT-2800..................................................................1
Safety Precautions......................................................................................................................................1
Test Personnel.............................................................................................................................1
Testing Area................................................................................................................................1
Safety Techniques ......................................................................................................................2
Using the HT-2800 Dielectric Withstand Tester....................................................................................2
Continuity Check.........................................................................................................................2
Ground Check Failures ...............................................................................................2
Defeating the Ground Check.....................................................................................3
Leakage Test................................................................................................................................3
Leakage Current Failures............................................................................................4
High Voltage Dielectric Withstand Test..................................................................................4
High Voltage Dielectric Withstand Test Failures...................................................4
High Voltage Discharge.............................................................................................4
Testing Equipment with non-Standard Plugs or Pigtail Operation......................................4
Introduction and Specifications................................................................................................................................5
Introduction.................................................................................................................................................5
Specifications...............................................................................................................................................5
Operation......................................................................................................................................................................7
Setting up your Tester................................................................................................................................7
AC Line Voltage Requirements.................................................................................................................7
Fuse Replacement.......................................................................................................................................7
Front and Rear Panel Features ..................................................................................................................7
Initial Checkout Procedure.........................................................................................................................12
Setting up the HT-2800 for Production Line Testing.............................................................................13
Factory Settings..........................................................................................................................13
Adjustment of the Leakage Current Level...............................................................................13
Adjustment of the High Voltage Ramp Time ..........................................................................14
Adjustment of the High Voltage Level....................................................................................14
Adjustment of the High Voltage Test Duration.....................................................................15
Setting the Ground Check Switch.............................................................................................15
Operating Techniques................................................................................................................................16
Daily Operation Test...................................................................................................................16
Testing..........................................................................................................................................16
Test Verification procedure when using the HTT-1 function checker:...............16
Test Verification procedure when NOT using the HTT-1 function
checker:.........................................................................................................................16
Test results...................................................................................................................................17
Hipot Pass....................................................................................................................17
Red LED/Buzzer...........................................................................................................17
Technical Assistance.................................................................................................................................................19
Maintenance and Calibration....................................................................................................................................21

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Introduction.................................................................................................................................................21
Service Information.....................................................................................................................................21
General Maintenance..................................................................................................................................21
Interior Access............................................................................................................................21
Calibration Access......................................................................................................21
Cleaning........................................................................................................................................22
Performance Test.........................................................................................................................................22
Calibration Procedure .................................................................................................................................23
Voltage Calibration Adjustment................................................................................................23
Continuity Calibration Adjustment..........................................................................................24

1
Section 1
An Introduction to Dielectric Withstand Testing with the HT-2800
The continuity test/dielectric withstand test is a production line test which is recognized by safety
agencies worldwide as a valid criterion of safe assembly of end-use equipment. The test ensures that the
primary circuit power and ground conductors were properly wired and connected for safe operation. It also
applies a high-voltage potential between power and ground conductors to make sure that no unintentional
leakage or arcing paths exist between power and ground. The test consists of a continuity check, a leakage
current check and a high voltage check. It is non-destructive to the equipment under test, and can be
accomplished in a short time.
Safety Precautions
The dielectric withstand test generates voltages of up to 2800 volts dc at potentially lethal current
levels. Currents of as little as 5 mA at 120 volts can cause death, and the HT-2800 is capable of generating 5
mA at up to 2800 volts. Because there is no zero volts crossing point as there is for ac voltage, dc voltage is
considered the more dangerous of the two. It is more likely that a person will be thrown clear or be able to
extricate himself from ac because of the zero crossing. The HT-2800 has been designed to minimize exposure
to high voltages. However, the potential for serious injury or death exists and personnel should be aware
when they conduct this test.
Test Personnel
Personnel require special training to conduct the dielectric withstand test. They should
understand electrical fundamentals clearly, and be aware that high voltage is adept and creative at
completing a path to ground. Instructions should include a warning against any metal jewelry. Operators
should not allow others in the testing area, especially when tests are being conducted. Organization is to be
stressed. The operator should keep the area free of unused leads and equipment.
Testing Area
The area used for conducting the dielectric withstand test should be as remote as possible from
normal production line activities. Only personnel actually conducting the test should be allowed in the area,
and it should be taped or roped off to preclude casual entry by other employees. In addition, the area
should be marked "WARNING -HIGH VOLTAGE TESTING" or the equivalent to warn others of the nature
of the testing taking place.
The bench being used should be non-conductive, and any exposed metal parts should be tied
together and grounded. If a conductive surface must be used, it should be grounded.
Because of sparking during a dielectric test failure, it is not safe to conduct dielectric withstand
tests in combustible atmospheres.